Apparatus and associated method for forming a filter component of a smoking article

ABSTRACT

An apparatus and associated method are provided for forming a rod member for use in the manufacture of cigarette filter elements. A fibrillation unit is configured to fibrillate a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith. A rod-forming unit is operably engaged with the fibrillation unit and is configured to form the fibrillated sheet material into a continuous filter rod member.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

Aspects of the present disclosure relate to smoking articles, and, more particularly, to apparatuses and associated methods for forming a filter element of a smoking article, such as a cigarette.

2. Description of Related Art

Popular smoking articles, such as cigarettes, have a substantially cylindrical rod shaped structure and include a charge, roll or column of smokable material such as shredded tobacco (e.g., in cut filler form) surrounded by a paper wrapper thereby forming a so-called “smokable rod” or “tobacco rod.” Normally, a cigarette has a cylindrical filter element aligned in an end-to-end relationship with the tobacco rod. Typically, a filter element comprises cellulose acetate tow plasticized using triacetin, and the tow is circumscribed by a paper material known as “plug wrap.” A cigarette can incorporate a filter element having multiple segments. In some instances, one of those segments can comprise activated charcoal particles. Typically, the filter element is attached to one end of the tobacco rod using a circumscribing wrapping material known as “tipping paper.” It also has become desirable to perforate the tipping material and plug wrap, in order to provide dilution of drawn mainstream smoke with ambient air. Descriptions of cigarettes and the various components thereof are set forth Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). A cigarette is employed by a smoker by lighting one end thereof and burning the tobacco rod. The smoker then receives mainstream smoke into his/her mouth by drawing on the opposite end (e.g., the filter end) of the cigarette.

It may sometimes be desirable to enhance the sensory attributes of cigarette smoke by applying additives to tobacco and/or by otherwise incorporating flavoring materials into various components of a cigarette. See, Leffingwell et al., Tobacco Flavoring for Smoking Products, R.J. Reynolds Tobacco Company (1972). For example, one type of tobacco flavoring additive is menthol. See, Borschke, Rec. Adv. Tob. Sci., 19, p. 47-70, 1993. Various proposed methods for modifying the sensory attributes of cigarettes have involved suggestion that filter elements may be used as vehicles for adding flavor to the mainstream smoke of those cigarettes. U.S. Pat. No. 6,761,174 to Jupe et al. proposes the placement of adsorbent and flavor-releasing materials in a cigarette filter. U.S. Pat. No. 6,584,979 to Xue et al. proposes the placement of fibers containing small particle size adsorbents/absorbents in the filter. U.S. Pat. Nos. 4,941,486 to Dube et al. and 4,862,905 to Green, Jr. et al. propose the placement of a flavor-containing pellet in a cigarette filter. Other representative types of cigarette filters incorporating flavoring agents are set forth in U.S. Pat. Nos. 3,972,335 to Tiggelbeck et al.; 4,082,098 to Owens, Jr.; 4,281,671 to Byrne; 4,729,391 to Woods et al.; and 5,012,829 to Thesing et al.

Cigarettes having adjustable filter elements that allow smokers to select the level of flavor that is available for transfer into mainstream smoke have been proposed. See, for example, U.S. Pat. Nos. 4,677,995 to Kallianos et al. and 4,848,375 to Patron et al. Some proposed cigarettes may be manipulated, reportedly for the purpose of providing components of their filter elements with the propensity to modify the nature or character of mainstream smoke. See, for example, U.S. Pat. Nos. 3,297,038 to Homburger; 3,339,557 to Karalus; 3,420,242 to Boukar; 3,508,558 to Seyburn; 3,513,859 to Carty; 3,596,665 to Kindgard; 3,669,128 to Cohen; and 4,126,141 to Grossman.

Some proposed cigarettes may have a hollow object positioned in their filter element, and the contents of that object is reportedly released into the filter element upon rupture of the object in the attempt to alter the nature or character of the mainstream smoke passing through the filter element. See, for example, U.S. Pat. Nos. 3,339,558 to Waterbury; 3,366,121 to Carty; 3,390,686 to Irby, Jr. et al.; 3,428,049 to Leake; 3,547,130 to Harlow et al; 3,575,1809 to Carty; 3,602,231 to Dock; 3,625,228 to Dock; 3,635,226 to Horsewell et al.; 3,685,521 to Dock; 3,916,914 to Brooks et al.; 3,991,773 to Walker; 4,889,144 to Tateno et al.; 7,578,298 to Karles et al.; and 7,115,085 to Deal; U.S. Pat. Application Pub. Nos. 2004/0261807 to Dube et al; 2007/0095357 to Besso et al.; 2007/0012327 to Karles et al.; 2006/0144412 to Mishra et al.; and 2006/0112964 to Jupe et al.; and PCT WO 03/009711 to Kim and WO 2007/060543 to Besso et al. Some proposed cigarettes may also have a capsule positioned in the filter element, and the contents of that capsule reportedly released into the filter element upon rupture of the capsule in order to deodorize the filter element after the cigarette is extinguished. See, for example, U.S. Pat. No. 6,631,722 to MacAdam et al.

Commercially marketed “Rivage” brand cigarettes have included a filter possessing a cylindrical plastic container containing water or a liquid flavor solution. Cigarettes representative of the “Rivage” brand cigarettes are described in U.S. Pat. Nos. 4,865,056 to Tamaoki et al. and 5,331,981 to Tamaoki et al., both of which are assigned to Japan Tobacco, Inc. The cylindrical casing within the filter reportedly may be deformed upon the application of external force, and a thin wall portion of the casing is consequently broken so as to permit release of the liquid within the casing into an adjacent portion of that filter.

Certain cigarettes incorporate filter elements having adsorbent materials dispersed therein, such as activated carbon or charcoal materials (collectively, carbonaceous materials) in particulate or granular form (i.e., powder). For example, an exemplary cigarette filter can possess multiple segments, and at least one of those segments can comprise particles of high carbon-content materials. Various types of filters incorporating charcoal particles or activated carbon types of materials are set forth in U.S. Pat. Nos. 2,881,770 to Touey; 3,101,723 to Seligman et al.; 3,236,244 to Irby et al.; 3,311,519 to Touey et al.; 3,347,247 to Lloyd; 3,349,780 to Sublett et al.; 3,370,595 to Davis et al.; 3,413,982 to Sublett et al.; 3,602,231 to Dock; 3,972,335 to Tigglebeck et al.; 5,360,023 to Blakley et al.; and 6,537,186 to Veluz; U.S. Pat. Publication No. 2007/0056600 to Coleman, III et al.; PCT WO 2006/064371 to Banerjea et al. and PCT WO 2006/051422 to Jupe et al.; which are incorporated herein by reference.

As mentioned, such carbonaceous material types are typically in the form of particles or granules when incorporated into the filter elements. For example, granules of carbonaceous material can be incorporated into “dalmation” types of filter regions using the general types of techniques used for traditional dalmation filter manufacture. Techniques for production of dalmation filters are known, and representative dalmation filters have been provided commercially by Filtrona Greensboro Inc. Alternatively, granules of carbonaceous material can be incorporated into “cavity” types of filter regions using the general types of techniques used for traditional “cavity” filter manufacture. Alternatively, other known types of techniques and equipment for producing filter segments incorporating granular materials can be suitably altered so as to introduce carbonaceous material into the filter segments. However, such techniques often are rudimentary in that the particulates or granules of carbonaceous material are roughly inserted into the filter element as either a loose powder or a slurry, a process which can be described as, for example, inconsistent, wasteful, and “messy.”

It may also be desirable to provide a smoker with the ability to enhance a sensory aspect of his/her smoking experience, such as can be accomplished by allowing the smoker to purposefully select a cigarette having certain characteristics or behaviors. That is, it may be desirable to allow the smoker to select a cigarette based on an indicated character or nature In particular, it may be desirable to provide a cigarette that is capable of enhancing the sensory attributes of the mainstream smoke (e.g., by flavoring that smoke). More particularly, it may be desirable to facilitate the manufacture of such cigarettes incorporating such flavor agents and the like, in a rapid, highly-automated fashion.

In this regard, some prior art processes and apparatuses for providing cigarettes, particularly filter elements thereof, with such desirable characteristics or behaviors are generally directed to associating the characteristic/behavior enhancement measure with the filter element during or after formation of the rod member from which the individual filter elements are obtained. As such, in some instances, the “formed” rod member may have to be at least partially “un-formed” in order to have the characteristic/behavior enhancement measure inserted therein or otherwise associated therewith. For example, cellulose acetate tow may be gathered to form a cylindrical composite forming the rod member, wherein the cylindrical composite must subsequently be longitudinally divided in order to insert the characteristic/behavior enhancement measure, before the cylindrical composite is wrapped to form the rod member. In such instances, the composite dividing and insertion unit may adversely affect the rod member manufacturing speed. In addition, there is a risk that the characteristic/behavior enhancement measure may be improperly inserted into the cylindrical composite or may be otherwise defective. As such, the characteristic/behavior enhancement measure may not necessarily perform as desired after the cigarette is formed. Still further, since the characteristic/behavior enhancement measure is added or otherwise associated with the cylindrical composite after that composite is formed, the characteristic/behavior enhancement measure may not necessarily interact with the composite in a uniform manner when activated to do so by the smoker.

As such, there exists a need for apparatuses and methods capable of associating a characteristic/behavior enhancement measure with the filter segments/elements of a smoking article in a manner facilitating a faster and more efficient formation process. Further, such apparatuses and methods should desirably be able to selectively impart other characteristics/behaviors, or combinations of such characteristics/behaviors, to the filter element, without significantly changing the formation process or requiring significant additional equipment.

BRIEF SUMMARY OF THE DISCLOSURE

The above and other needs are met by aspects of the present disclosure, wherein one such aspect relates to an apparatus and associated method for forming a rod member for use in the manufacture of cigarette filter elements, wherein the rod member defines a longitudinal axis. A fibrillation unit is configured to fibrillate a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith. A rod-forming unit is operably engaged with the fibrillation unit and is configured to form the fibrillated sheet material into a continuous filter rod member.

In particular aspects, a rod-dividing unit may be configured to subdivide the continuous filter rod member, at selected intervals along the longitudinal axis thereof, into a plurality of filter rod portions each having a portion of the fibrillated sheet material therein. Further, an applicator unit may be configured to apply a material layer, or a plurality of successive material layers, to the sheet material prior to the fibrillation unit fibrillating the sheet material. At least one of the one or more material layers may be applied to the sheet material as one of a coating, a co-extrusion, and a laminate. The fibrillating unit may also be configured to fibrillate the sheet material, such as cellulose acetate, to form a plurality of fibrous elements, wherein the fibrous elements are at least partially interconnected. In some aspects, a crimping unit may be configured to crimp the sheet material, or an embossing unit may be configured to emboss the sheet material, prior to the fibrillation unit fibrillating the sheet material.

Aspects of the apparatus may incorporate equipment for supplying a continuous supply of fibrillated sheet material, having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith, to form a continuous filter rod (e.g., a filter material processing unit adapted to supply filter material to a continuous rod forming unit). The filter material is formed into a continuous filter rod that is then is subdivided at predetermined axial intervals so as to form a plurality of filter rods or filter rod portions, such that each filter rod portion defines a plurality of cigarette filter elements, each having a portion of the fibrillated sheet material therein.

Aspects of the present disclosure thus address the identified needs and provide other advantages as otherwise detailed herein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a schematic of a rod-making apparatus including a portion of the filter tow processing unit, a fibrillation unit, an applicator unit, a crimping unit, an embossing unit, and a filter rod-forming unit, according to one aspect of the present disclosure;

FIG. 2 is a schematic of a fibrillation unit for fibrillating a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith, according to one aspect of the present disclosure;

FIG. 3A is a perspective view of a fibrillation needle bar assembly capable of implementation in a fibrillation unit for fibrillating a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith, the fibrillation needle bar assembly including a plurality of fibrillation bar members, according to one aspect of the present disclosure;

FIG. 3B is perspective view of a fibrillation bar member capable of implementation in various aspects of the present disclosure;

FIG. 3C is a perspective view of a fibrillation roller assembly capable of implementation in a fibrillation unit for fibrillating a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith, according to one aspect of the present disclosure;

FIG. 3D is a schematic of an exemplary fibrillated sheet material, according to one aspect of the present disclosure; and

FIG. 4 is a cross-sectional view of a composite sheet material having a plurality of layers, according to one aspect of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Cigarette rods may be manufactured using a cigarette making machine, such as a conventional automated cigarette rod making machine. Exemplary cigarette rod making machines are of the type commercially available from Molins PLC or Hauni-Werke Korber & Co. KG. For example, cigarette rod making machines of the type known as MkX (commercially available from Molins PLC) or PROTOS (commercially available from Hauni-Werke Korber & Co. KG) can be employed. A description of a PROTOS cigarette making machine is provided in U.S. Pat. No. 4,474,190 to Brand, at col. 5, line 48 through col. 8, line 3, which is incorporated herein by reference. Types of equipment suitable for the manufacture of cigarettes also are set forth in U.S. Pat. Nos. 4,781,203 to La Hue; 4,844,100 to Holznagel; 5,156,169 to Holmes et al.; 5,191,906 to Myracle, Jr. et al.; 6,647,870 to Blau et al.; 6,848,449 to Kitao et al.; 6,904,917 to Kitao et al.; 7,210,486 to Hartmann; 7,234,471 to Fitzgerald et al.; 7,275,548 to Hancock et al.; and 7,281,540 to Barnes et al.; each of which is incorporated herein by reference.

The components and operation of conventional automated cigarette making machines will be readily apparent to those skilled in the art of cigarette making machinery design and operation. For example, descriptions of the components and operation of several types of chimneys, tobacco filler supply equipment, suction conveyor systems and garniture systems are set forth in U.S. Pat. Nos. 3,288,147 to Molins et al.; 3,915,176 to Heitmann et al; 4,291,713 to Frank; 4,574,816 to Rudszinat; 4,736,754 to Heitmann et al. 4,878,506 to Pinck et al.; 5,060,665 to Heitmann; 5,012,823 to Keritsis et al. and 6,360,751 to Fagg et al.; and U.S. Patent Application Publication No. 2003/0136419 to Muller; each of which is incorporated herein by reference. The automated cigarette making machines of the type set forth herein provide a formed continuous cigarette rod or smokable rod that can be subdivided into formed smokable rods of desired lengths.

Filtered cigarettes incorporating filter elements provided from filter rods that are produced in accordance with the present disclosure can be manufactured using traditional types of cigarette making techniques. For example, so-called “six-up” filter rods, “four-up” filter rods and “two-up” filter rods that are of the general format and configuration conventionally used for the manufacture of filtered cigarettes can be handled using conventional-type or suitably modified cigarette rod handling devices, such as tipping devices available as Lab MAX, MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co. KG. See, for example, the types of devices set forth in U.S. Pat. Nos. 3,308,600 to Erdmann et al.; 4,281,670 to Heitmann et al.; 4,280,187 to Reuland et al.; 6,229,115 to Vos et al.; 7,296,578 to Read, Jr.; and 7,434,585 to Holmes; each of which is incorporated herein by reference. The operation of those types of devices will be readily apparent to those skilled in the art of automated cigarette manufacture.

Cigarette filter rods that are produced in accordance with the present disclosure can be used to provide multi-segment filter rods. Such multi-segment filter rods can be employed for the production of filtered cigarettes possessing multi-segment filter elements. An example of a two-segment filter element is a filter element possessing a first cylindrical segment incorporating activated charcoal particles (e.g., a “dalmation” type of filter segment) at one end, and a second cylindrical segment that is produced from a filter rod produced in accordance with aspects of the present disclosure. The production of multi-segment filter rods can be carried out using the types of rod-forming units that have been employed to provide multi-segment cigarette filter components. Multi-segment cigarette filter rods can be manufactured using a cigarette filter rod making device available under the brand name Mulfi from Hauni-Werke Korber & Co. KG of Hamburg, Germany.

Various types of cigarette components, including tobacco types, tobacco blends, top dressing and casing materials, blend packing densities; types of paper wrapping materials for tobacco rods, types of tipping materials, and levels of air dilution, can be employed. See, for example, the various representative types of cigarette components, as well as the various cigarette designs, formats, configurations and characteristics, which are set forth in U.S. Pat. Nos. 5,220,930 to Gentry, 6,779,530 to Kraker, 7,565,818 to Thomas et al., and 7,237,559 to Ashcraft et al.; and U.S. Patent Application Publication Nos. 2005/0066986 to Nestor et al. and 2007/0246055 to Oglesby; each of which is incorporated herein by reference.

Filter rods can be manufactured pursuant to aspects of the present disclosure using a rod-making apparatus, and an exemplary rod-making apparatus includes a rod-forming unit. Representative rod-forming units are available as KDF-2 and KDF-3E from Hauni-Werke Korber & Co. KG; and as Polaris-ITM Filter Maker from International Tobacco Machinery. In a conventional process, filter material, such as cellulose acetate filamentary tow, is typically processed using a conventional filter tow processing unit. For example, filter tow can be bloomed using bussel jet methodologies or threaded roll methodologies. An exemplary tow processing unit has been commercially available as E-60 supplied by Arjay Equipment Corp., Winston-Salem, N.C. Other exemplary tow processing units have been commercially available as AF-2, AF-3 and AF-4 from Hauni-Werke Korber & Co. KG. and as Candor-ITM Tow Processor from International Tobacco Machinery. Other types of commercially available tow processing equipment, as are known to those of ordinary skill in the art, can be employed. Other types of filter materials, such as gathered paper, nonwoven polypropylene or polyolefin web or gathered strands of shredded web, can be provided using the types of materials, equipment and techniques set forth in U.S. Pat. Nos. 3,805,682 to Lyon et al.; 4,763,674 to Lelah; 4,807,809 to Pryor et al.; 4,811,745 to Cohen et al.; 4,903,714 to Barnes et al.; 4,925,602 to Hill et al.; 5,025,814 to Raker; 5,101,839 to Jakob et al.; 5,246,017 to Saintsing et al.; 5,271,419 to Arzonico et al.; 5,360,023 to Blakely et al.; 5,404,890 to Gentry et al.; and 5,568,819 to Gentry et al. In some instances, fibers of the filamentary tow may be fibrillated prior to being processed such as set forth, for example, in U.S. Pat. No. 4,273,600 to Luke and U.S. Pat. No. 4,700,723 to Yoshikawa et al. In addition, representative manners and methods for operating a filter material supply units and filter-making units are set forth in U.S. Pat. Nos. 4,281,671 to Bynre; 4,850,301 to Green, Jr. et al.; 4,862,905 to Green, Jr. et al.; 5,060,664 to Siems et al.; 5,387,285 to Rivers and 7,074,170 to Lanier, Jr. et al. In yet other instances, some have modified the filter itself to promote degradability, for example, by providing slits in the filter, as set forth in U.S. Patent Application Publication No. US 2004/0139977 A1 to Garthaffner.

Representative types of filter rods incorporating objects, and representative types of cigarettes possessing filter elements incorporating objects, such as flavor-containing capsules or pellets, can possess the types of components, format and configuration, and can be manufactured using the types of techniques and equipment set forth in U.S. Patent Application Publication No. 2008/0029118 A1 to Nelson et al.; and U.S. Pat. Nos. 7,115,085 to Deal, 4,862,905 to Green, Jr. et al., and 7,479,098 to Thomas et al.; which are incorporated herein by reference in their entireties.

FIG. 1 schematically illustrates an exemplary rod-making apparatus 210 that may be at least partially implemented in forming filter rods or filter rod portions 205 according to aspects of the present disclosure. An exemplary rod-making apparatus 210 includes a rod-forming unit 212 (e.g., a KDF-2 unit available from Hauni-Werke Korber & Co. KG) suitably adapted to process a continuous length of sheet-form filter material 40 into a continuous filter rod 220. In accordance with aspects of the present disclosure, the continuous length of sheet-form filter material may originate and be supplied in sheet form from a source (not shown) such as a bobbin, reel/roll, spool or the like. Such a sheet of the filter material 40 may be formed in many different manners, as will be appreciated by one skilled in the art, for example, as a nonwoven web in a melt blowing process (see, e.g., U.S. Pat. No. 3,978,185 to Buntin et al.; European Patent Publication No. EP 0330709 A1 to Radwanski et al.)

The rod-making apparatus 210 generally includes a filter material processing assembly 218 configured to process the filter material 40 before the processes filter material 40 is passed through the rod-forming unit 212 to form the continuous rod 220. In this regard, in one aspect, the filter material processing assembly 218 may include a fibrillation unit 400 configured to receive the sheet material from the source and to fibrillate the sheet filter material 40, prior to formation of the fibrillated sheet of filter material 40 into the continuous filter rod 220 by the rod-forming unit 212. In some instances, the fibrillation unit 400 may be configured to separately fibrillate two or more sheets of the same or different material such as, for example, two sheets of cellulose acetate, or a sheet of cellulose acetate and a sheet of cellophane, wherein the two or more separately fibrillated sheets may then be combined upon entering the rod-forming unit 212. As used herein, the terms “fibrillate” and variations thereof are used to describe the process in which longitudinal cuts or slits are imparted to the sheet filter material 40 whereby the sheet is cut or otherwise slit, either partially or entirely, into fibrous or fiber-like elements. Such cuts or slits may be imparted along the longitudinal direction of the continuous sheet of filter material 40 (i.e., along the processing or feed direction of the sheet). In some instances, the fibrous or fiber-like elements of the fibrillated sheet may be at least partially interconnected to form, for example, a general lattice-type structure upon lateral expansion of the fibrillated sheet, as shown schematically in FIG. 3D. A representative fibrillation unit suitable for implementation with various aspects of the filter material processing assembly 218 of the rod-making apparatus 210 disclosed herein may include, for example, a suitably modified fibrillation unit available from CHRISTOPH BURCKHARDT AG for forming the cuts or slits in the sheet filter material 40.

According to some aspects, as will be appreciated by one skilled in the art, the fibrillation unit 400 may comprise a fibrillation roller assembly 402 configured to interact with the sheet of filter material 40 so as to fibrillate the sheet material, as shown schematically in FIG. 2. In one instance, the fibrillation roller assembly 402 may include a fibrillating roller member 404 which is generally configured as a cylinder. A plurality of fibrillating pins or needle-like members, generally designated as 406, extend outwardly from an outer surface or periphery of the fibrillating roller member 404, and the pins or needle-like members 406 are configured to cut or otherwise slit the sheet of filter material 40 as the sheet material passes over or otherwise engages the fibrillating roller member 404 During the fibrillation process, the sheet filter material 40 is fed to the fibrillation unit 400 and appropriately directed and positioned by one or more guide rollers 408 for interaction with the fibrillating pins 406. The guide rollers 408 may be positioned adjacent to the fibrillating roller member 404 to provide guidance/tension for the sheet filter material 40. The fibrillating roller member 404 may be configured to rotate in the direction in which the sheet filter material 40 is moving or otherwise directed, such that the fibrillating pins 406 interact with the filter material 40 in the same direction. The circumferential or angular speed of the fibrillating roller member 404 may be approximately 15-30% higher than the speed at which the sheet filter material 40 advances in the machine direction. However, one skilled in the art will appreciate that such parameters may vary, as necessary or desired, to achieve the fibrillated sheet material as disclosed herein.

For example, as shown in FIG. 2, the filter material 40 may be fed in the feed direction A1, while the fibrillating roller member 404 rotates in direction A2. In some instances, the fibrillating pins 406 may be positioned on the fibrillating roller member 404 so as to have a negative inclination with respect to the filter material 40. That is, in some instances, the fibrillating pins 406 do not extend perpendicularly from the surface of the fibrillating roller member 404 but, instead, may be angled with respect thereto. For example, each fibrillating pin 406 disposed about the periphery of the fibrillating roller member 404 may form between about a 15 degree and about a 30 degree angle with respect to the surface thereof.

In some instances, the fibrillating pins 406 may be attached or otherwise operably engaged with a fibrillation bar 410, as shown in FIG. 3B. Each fibrillation bar 410 may be removably engaged with the fibrillating roller member 404 such that each fibrillation bar 410 may be readily removed for maintenance or replacement, as shown in FIG. 3A. For example, the fibrillating roller member 404 may define a plurality of channels 412 for receiving the fibrillation bars 410. In other instances, the fibrillating pins 406 may be permanently attached or affixed to the fibrillating roller member 404, as shown in FIG. 3C.

Preferred cigarettes generally exhibit a desirable resistance to draw. For example, an exemplary cigarette exhibits a pressure drop of between about 50 mm and about 200 mm water pressure drop at 17.5 cc/sec. air flow. Other preferred cigarettes exhibit pressure drop values of between about 70 mm and about 180 mm, more preferably between about 80 mm to about 150 mm water pressure drop at 17.5 cc/sec. air flow. Typically, pressure drop values of cigarettes are measured using a Filtrona Filter Test Station (CTS Series) available form Filtrona Instruments and Automation Ltd. In this regard, the sheet filter material fibrillation process conditions, as accomplished by the fibrillation unit 400 and/or the rod-forming unit 212, may be optimized to provide a fibrillated sheet that can be gathered and used to form the filter rod element of the cigarette, wherein the as-formed cigarette is capable of achieving desired pressure drop and filtration properties noted herein.

The filter material 40 can vary, and can be any sheet material of the type that can be employed for providing a tobacco smoke filter for cigarettes having the desired properties noted herein. Preferably, the filter material 40 can be cellulose acetate in sheet form. However, in some aspects, a sheet form of polyolefin (i.e., polypropylene), paper, reconstituted tobacco, or the like, may be suitable materials. In other aspects, the filter material 40 may comprise a sheet material incorporating one or more additives such as, for example, cellulose acetate incorporating one or more of TiO₂, starch, rayon fibers, activated carbon, or other suitable additive (i.e., a superabsorbent polymer). In other instances, the filter material 40 may comprise a sheet material filled with inorganic, organic, polymeric, and/or ceramic materials that may enhance functionality with regard, for example, to chemical filtration (i.e., by chemical reaction or catalysis), photodegradation, compostability, and/or bio-degradation. In yet other instances, metallization of the sheet filter material 40 may also enhance such functionality. In still other instances, the filter material 40 may comprise a sheet material printed with one or more biological agents such as, for example, enzymes, configured to facilitate one or more particular functions with regard, for instance, to smoke filtration or cigarette butt degradation in the presence of moisture, or water, or by interaction with a constituent in the smoke.

Once fibrillated, the filter material 40, such as cellulose acetate, may be processed using a conventional filter tow processing unit 218 such as a commercially available E-60 supplied by Arjay Equipment Corp., Winston-Salem, N.C. Other types of commercially available tow processing equipment, as are known to those of ordinary skill in the art, may similarly be used.

In some instances, the filter material 40 in sheet form may comprise a composite or coated sheet material having a plurality of layers, films, coatings, fillers, additives, and/or components, wherein each such layer, film, coating, filler, additive, and/or component may be comprised of a different material or otherwise comprise one of a biodegradability-enhancing substance and a compostability-enhancing substance. That is, the sheet of filter material 40 directed to the fibrillation unit 400 may include combinations of various types of materials, wherein the materials may include, for example, a base sheet of the primary filter material, such as cellulose acetate, having one or more layers, films, coatings, surface treatments, or other materials applied thereto or incorporated therein. One such coating may be, for example, a plasticizer such as triacetin which is normally applied to conventional filamentary tow in traditional amounts using known techniques. In other instances, the material applied to the base sheet may be applied in liquid form, and may comprise such substances as, for example, the aforementioned triacetin, carbowax, flavoring compounds, propylene glycol, tri-ethyl-citrate, or any other suitable substance. Further, in this regard, each layer, film, or coating applied to the base sheet may contribute some functionality or property to the formed filter rod portion, such as, for example, smoke filtering, smoke taste, water dispersibility, biodegradability, and/or compostability.

In one exemplary aspect, as shown in FIG. 4, the sheet filter material 40 may be comprised of three layers, wherein a starch layer 40 b may be deposited on a cellulose acetate layer 40 c, and then a water soluble polymer layer 40 a may be deposited on the starch layer 40 b. Such a layered sheet filter material 40 may, in some instances, be formed separately of the rod-making apparatus 210 (i.e., as a single sheet having the multiple layers), or may be formed through a combination of the layers within the rod-making apparatus 210. In other aspects, the filter material processing assembly 218 may further include an applicator unit 500 disposed prior to the fibrillation unit 400 and configured to apply one or more material layers to the base sheet material. In this regard, the applicator unit 500 may be configured to apply the material layer(s) to the base sheet material as one of a coating, a film, a layer, a surface treatment, a co-extrusion, and a laminate. One skilled in the art will appreciate, however, that the applicator unit 500 may be configured in many different manners for applying the one or more material layers to the base sheet material. In some desirable instances, the applicator unit 500 is configured to apply each of the one or more material layers in a consistent and uniform manner to the base sheet material. The material layers may be applied to one or both surfaces of the base sheet material and, in some instances, as successive layers on a surface of the base sheet material. Because the additional layers, films, coatings, or other substances are applied to the sheet filter material prior to fibrillation of the sheet and formation of the continuous filter rod 220, a more even and consistent distribution of the films/substances on the filter material can be achieved (i.e., as compared to applying such substances to a filamentary form of material). As such, a more even and consistent distribution of the films/coatings/substances can further be achieved throughout the continuous filter rod 220 since the films/coatings/substances are applied prior to fibrillation and thus already applied to the resulting fibrous material prior to forming the filter rod. One skilled in the art will appreciate, however, that in other instances, the applicator unit 500 may be disposed downstream of the fibrillation unit 400 for applying each of the one or more material layers to the fibrillated sheet material.

According to further aspects, the filter material processing assembly 218 may sometimes include a crimping unit 600 for crimping the sheet filter material 40 prior to the fibrillation unit 400 fibrillating the sheet filter material 40. In other instances, the crimping unit 600 may be disposed downstream of the fibrillation unit 400 so as to crimp the fibrillated sheet material. In addition to the crimping unit 600, or instead of the crimping unit 600, the filter material processing assembly 218 of the rod-making apparatus 210 may include an embossing unit 650 for embossing the sheet filter material 40 prior to the fibrillation unit 400 fibrillating the sheet filter material 40. In other instances, the embossing unit 650 may be disposed downstream of the fibrillation unit 400 so as to emboss the fibrillated sheet material. One skilled in the art will appreciate that crimping and/or embossing the sheet filter material 40 (i.e., the cellulose acetate sheet having the layers/coatings/films applied thereto) may increase the effective surface area of the fibrillated filter material and, in some instances, may thus increase the effect provided by the fibrillated filter material forming the filter rod.

Generally, the fibrillated sheet of filter material 40 processed using the filter material processing assembly 218 is passed through the rod-forming unit 212 to form the continuous filter rod 220, in some instances, as with conventional filter tow material. An object insertion unit 214 may be associated with the rod-making apparatus 210 to place/insert objects (not shown) within the formed composite of fibrillated filter material or the continuous filter rod 220. The continuous filter rod 220 can then be subdivided using a rod cutting assembly 222 into the plurality of rod portions 205 each having at least a portion of the fibrillated sheet of filter material 40 therein. The succession or plurality of rod portions 205 are collected for further processing in a collection device 226 which may be a tray, a rotary collection drum, conveying system, or the like. If desired, the rod portions can be transported directly to a cigarette making machine. In such a manner, in excess of 500 rod portions, each of about 100 mm in length, can be manufactured per minute.

More particularly, the continuous length of fibrillated sheet filter material 40 may be directed into a gathering region of the rod-forming unit 212 to form a cylindrical composite. The gathering region can have a tongue and horn configuration, a gathering funnel configuration, stuffer or transport jet configuration, or other suitable type of gathering mechanism. The tongue 232 provides for further gathering, compaction, conversion or formation of the cylindrical composite from block 230 into an essentially cylindrical (i.e., rod-like) shape whereby the fibrillated sheet having, in some instances, partially interconnected, fibers extends essentially along the longitudinal axis of the cylindrical composite so formed. The fibrillated sheet filter material 40, which has been formed into the cylindrical composite, is continuously received into the rod-forming unit 212 to form the continuous filter rod 220.

In some aspects, the fibrillated sheet filter material 40, which has been formed into the cylindrical composite, may be, for example, surrounded by an extruded polymeric shell comprised of a biodegradable polymer, such as polyvinyl alcohol, polylactic acid, polycaprolactone, polyhydroxyalkanoates, starch, or combinations thereof. Further, the polymeric shell may also comprise other substances such as, for instance, photoactive agents such as TiO₂, or water swellable polymers such as aerogels, starch grafted polymers, and/or superabsorbent polymers.

The cylindrical composite (or the cylindrical composite in a polymeric shell) is then fed into wrapping mechanism 234, which includes endless garniture conveyer belt 236 or other garniture mechanism. The garniture conveyer belt 236 is continuously and longitudinally advanced using an advancing mechanism 238, such as a ribbon wheel or cooperating drum, so as to transport the cylindrical composite through wrapping mechanism 234. The wrapping mechanism provides a strip of wrapping material 45 (e.g., non-porous paper plug wrap) to the outer surface of the cylindrical composite in order to produce a continuous wrapped filter rod 220.

Generally, the strip or web of wrapping material 45 is provided from rotatable bobbin 242. The wrapping material is drawn from the bobbin, is trained over a series of guide rollers, passes under block 230, and enters the wrapping mechanism 234 of the rod-forming unit. The endless garniture conveyer belt 236 transports both the strip of wrapping material and the cylindrical composite in a longitudinally extending manner through the wrapping mechanism 234 while draping or enveloping the wrapping material about the cylindrical composite.

The seam formed by an overlapping marginal portion of wrapping material has adhesive (e.g., hot melt adhesive) applied thereto at applicator region 244 in order that the wrapping material can form a tubular container for the filter material. Alternatively, the hot melt adhesive may be applied directly upstream of the wrapping material's entry into the garniture of the wrapping mechanism 234 or block 230, as the case may be. The adhesive can be cooled using chill bar 246 in order to cause rapid setting of the adhesive. It is understood that various other sealing mechanisms and other types of adhesives can be employed in providing the continuous wrapped rod.

The continuous wrapped rod 220 passes from the sealing mechanism and is subdivided (e.g., severed) at regular intervals at the desired, predetermined length using cutting assembly 222, which may include as a rotary cutter, a highly sharpened knife, or other suitable rod cutting or subdividing mechanism. It is particularly desirable that the cutting assembly does not flatten or otherwise adversely affect the cross-sectional shape of the rod. The rate at which the cutting assembly severs the continuous rod at the desired points is controlled via an adjustable mechanical gear train (not shown), or other suitable mechanism.

Referring to FIG. 1, control of the disclosed process may be accomplished using a control system including control hardware and/or software. An exemplary control system 290 can incorporate a Siemens 315-2DP Processor, a Siemens FM352-5 (Boolean processor) and a 16 input bit/16 output bit module. Such a system can utilize a system display 293, such as a Siemens MP370. A typical rod-making unit may possess internal controls whereby, for a rod of desired length, the speed of the knife of the severing unit is timed relative to the speed of continuous rod formation. A first encoder 296, by way of connection with the drive belt of the rod-making unit, and with the control unit 299 of the insertion unit 214, provides reference of the knife position of the cutting assembly relative to the wheel position of the insertion unit 214. An exemplary first encoder is available as Heidenhain Absolute 2048.

The rod-making apparatus optionally can be equipped with a system adapted to provide information associated with rod production and operation event analysis. For example, a rod-making apparatus, such as a commercially available KDF-2 type of unit, can be adapted so as to be equipped with a central processing unit. A representative central processing unit is available as a Siemens 314-C processor. The central processing unit is equipped with input and output modules. As such, the operation of the rod-making unit can be monitored, and data so generated can be transferred to the central processing unit. In addition, data received by the central processing unit can be presented on a video touch screen or retrieved by a high level operating system (e.g., via an Ethernet). A remote unit such as Siemens IM-153 equipped with inputs, outputs and a counter module available as Siemens FM350-2 installed in sending unit collects data provided to the central processing unit using a bus system (e.g., Profibus). Depending upon information gathered, data that can be generated may relate to number of rods manufactured during a particular time frame, machine operating speed, manufacturing efficiency, number of stops, filters sent to a making machine and stoppage reasons.

Many modifications and other aspects of the disclosures set forth herein will come to mind to one skilled in the art to which these disclosures pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, a biodegradable and compostable filter may be formed using a fibrillated cellulose diacetate film, according to the principles and methods disclosed herein, wherein the cellulose diacetate film is certified to be biodegradable and compostable according to ASTM criteria. By implementing the aforementioned cellulose diacetate film, a biodegradable and compostable filter may be achieved while potentially not negatively impacting the smoke taste and/or other filter characteristics due to the similarities with the cellulose acetate material used in conventional filters. It follows that any suitable film, sheet, or layer of material having a biodegradability-enhancing substance and/or a compostability-enhancing substance associated therewith (while desirably not negatively impacting the smoke taste and/or other filter characteristics), implemented in the disclosed fibrillation process, is within the spirit and scope of the present disclosure. Therefore, it is to be understood that the disclosures are not to be limited to the specific aspects disclosed and that modifications and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. An apparatus for forming a rod member for use in the manufacture of cigarette filter elements, the rod member defining a longitudinal axis, the apparatus comprising: a fibrillation unit configured to fibrillate a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith; and a rod-forming unit operably engaged with the fibrillation unit and configured to form the fibrillated sheet material into a continuous filter rod member.
 2. An apparatus according to claim 1, further comprising a rod-dividing unit configured to subdivide the continuous filter rod member, at selected intervals along the longitudinal axis thereof, into a plurality of filter rod portions each having a portion of the fibrillated sheet material therein.
 3. An apparatus according to claim 1, further comprising an applicator unit configured to apply a material layer to the sheet material prior to the fibrillation unit fibrillating the sheet material.
 4. An apparatus according to claim 1, wherein the applicator unit is configured to apply a plurality of successive layers to the sheet material prior to the fibrillation unit fibrillating the sheet material.
 5. An apparatus according to claim 1, wherein the fibrillating unit is configured to fibrillate the sheet material to form a plurality of fibrous elements, the fibrous elements being at least partially interconnected.
 6. An apparatus according to claim 1, further comprising a crimping unit configured to crimp the sheet material prior to the fibrillation unit fibrillating the sheet material.
 7. An apparatus according to claim 1, further comprising an embossing unit configured to emboss the sheet material prior to the fibrillation unit fibrillating the sheet material.
 8. An apparatus according to claim 1, further comprising an applicator unit configured to apply at least one material layer to the sheet material as one of a coating, a co-extrusion, and a laminate, prior to the fibrillation unit fibrillating the sheet material.
 9. An apparatus according to claim 1, wherein the fibrillation unit is further configured to fibrillate a sheet material comprising cellulose acetate.
 10. An apparatus according to claim 1, wherein the rod forming unit is further configured to gather the fibrillated sheet material into a cylindrical composite prior to forming the continuous filter rod member.
 11. A method of forming a rod member for use in the manufacture of cigarette filter elements, the rod member defining a longitudinal axis, the method comprising: fibrillating a sheet material with a fibrillation unit, the sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith; and forming the fibrillated sheet material into a continuous filter rod member with a rod-forming unit operably engaged with the fibrillation unit.
 12. A method according to claim 11, further comprising subdividing the continuous filter rod member, at selected intervals along the longitudinal axis thereof, into a plurality of filter rod portions each having a portion of the fibrillated sheet material therein with a rod-dividing unit.
 13. A method according to claim 11, further comprising applying a material layer to the sheet material, prior to fibrillating the sheet material, with an applicator unit.
 14. A method according to claim 11, further comprising applying a plurality of successive layers to the sheet material, prior to fibrillating the sheet material, with an applicator unit.
 15. A method according to claim 11, wherein fibrillating a sheet material further comprises fibrillating the sheet material to form a plurality of fibrous elements, the fibrous elements being at least partially interconnected.
 16. A method according to claim 11, further comprising crimping the sheet material, prior to fibrillating the sheet material, with a crimping unit.
 17. A method according to claim 11, further comprising embossing the sheet material, prior to fibrillating the sheet material, with an embossing unit.
 18. A method according to claim 11, further comprising applying at least one material layer to the sheet material, with an applicator unit, as one of a coating, a co-extrusion, and a laminate, prior to fibrillating the sheet material.
 19. A method according to claim 11, wherein fibrillating a sheet material further comprises fibrillating a sheet material comprising cellulose acetate.
 20. A method according to claim 11, further comprising gathering the fibrillated sheet material into a cylindrical composite prior to forming the continuous filter rod member. 